Custom Aero




Thurston Bros. has developed a worry-free custom Aero ordering process that makes getting your dream jacket an enjoyable and gratifying experience! There are many choices to make in this process.  One must choose leather, color, hardware, liner, etc., but the first step is to get the right size.  Thurston Bros. offers customers over a decade of experience in getting perfect fits for Aero jackets.  We know the ins and outs of the fit and design of every one of the 100+ Aero styles you can choose from and we'll guide you through the entire custom process.  Join thousands of satisfied Thurston Bros. customers by beginning your custom Aero order...Thurston makes it easy!


Step One: Fit Jacket and Hide Samples

Thurston Bros. believes in getting the fit that is right for YOU! At all times we have all sizes, 32 through 52, in stock and ready to ship, in a variety of Aero styles and leathers. When you are ready to order, we send you a stock Aero jacket that will be used as a "fit jacket" for your custom order. Fit jackets take the guesswork out of the fitting process! We'll use this jacket to assess if the body fit is correct. We'll also determine if you need a longer or shorter sleeve length, as well as if you need a longer or shorter body length. You'll return the fit jacket to us (unless, of course, you love it and want to keep it!) and we'll use the information gathered from the fitting to write up the specifications for your custom order. Hide samples are sent with the fit jacket so that customers can make an informed leather selection. The shipping cost to receive a Thurston Bros. fit jacket is $39.99 for US Customers, $60.00 for Canadian Customers, $120 for Australia and New Zealand, and $95.00 for all other International Customers (we use USPS Priority International or UPS Worldwide).  Customers pay the base price of the style, plus shipping, to get a stock jacket shipped out for the fitting.  Contact us at to get started!


*Make sure to take photos of yourself in the fit jacket before shipping it back. We'll need to see photos of the jacket zipped up, front and back.


Customers are required to pay return shipping for the fit jacket back to Thurston Bros. Once the deposit payment on the fitting process has been paid, the custom process has started and there are no refunds permitted.  Please see our Store Policies page for more information.


We offer several convenient payment options for our custom jackets.  We take all major credit cards, including Visa, Mastercard, American Express and Discover.  You can also pay using your Paypal account.  Lastly, we offer AFFIRM, which is a payment plan that gives a variety of payment schedules and interest rates. 


Step Two: Customizing Options

Our most popular leather choices are Vicenza Horsehide, Chromexcel Steerhide and Chromexcel Front Quarter Horsehide (FQHH). Vicenza Horsehide is a vegetable tanned mid-weight horsehide. Chromexcel is a combination tanned leather that is made exclusively by the Horween Leather Company in Chicago, IL. Other great choices include Goatskin, Battered Steerhide and Jerky Horsehide. Vicenza, Pinnacle and Unfinished Horsehide have an up-charge of $125.00.  High Grain Jerky Horsehide is $75.00.  We also have Badalassi Cowhide available for an up-charge of $150.00, as well as Bainbridge and Vancouver Cowhide for an up-charge of $250.00.  All other hides are included in the base price of the custom jacket.

Leather Colors
Vicenza Horsehide is available in Black, Blackened Brown, Dark Seal, Seal, Cordovan, Russet, Natural, Navy Blue, Olive and Cream.

Chromexcel Steerhide is available in Black, Brown and Cordovan. Chromexcel FQHH is available in Black, Brown, Cordovan, Natural, Midnight Blue, Tumbled Black, Tumbled Brown and Tumbled Cordovan.

Bainbridge Cowhide is offered in Black, Dark Maple and Chestnut.  Vancouver Cowhide is offered in Dark Hickory.

Badalassi Cowhide is offered in Black, Chestnut, Tobacco and Russet.

Pinnacle Horsehide is available in Black, Brown and Cognac.

Goatskin comes in Black, Seal and Russet.

We also offer Battered Steerhide and Jerky Horsehide.

To view the variety of leather color options, please go to our Instagram page: @thurstonbros    



There is an incredible variety of choices for a custom lining. There are cotton and wool tartans from the Lochcarron Mill in Scotland, as well as traditional cotton drills, Lochcarron Tweeds, Harris Tweeds, Alpaca Wool, and light cotton sateens. Linings cost as follows--

Cotton Tartan (Bute, Lanark and Royal Stewart)--Free, included in jacket price

Cotton Sateen (Black, Dark Navy, Olive, Wine and Emerald Green)--Free, included in jacket price

Cotton Drill (Black, Brown, Olive and Red)--Free, included in jacket price

Wild Card Wool Tartan (Give us the base color you would like and Aero will pick a premium Lochcarron tartan from their collection of remnants)--$40.00

Regular Stock Wool (Royal Stewart, Black Stewart, Isle of Skye, Buchanan Hunting Modern, Minto Check Tweed, MacKenzie Weathered, Buchanan Blue, Rob Roy heavyweight and Auld Scotland)--$80.00

Special Order Lochcarron Wool (All Lochcarron Tartans and Tweeds listed on the Lochcarron website)--$110.00  *To choose from a complete list of wool tartans, go to this link: Lochcarron Of Scotland

Herringbone Tweed Wool (Brown and Navy)--$45.00

Corduroy (Black, Brown and Navy)--$50.00

Moleskin (Black, Brown and Navy)--$50.00

Quilted Lining--$80.00 (Sunset Red Rayon, Petrol Blue Rayon and Navy Cotton Sateen)

Melton Wool (Black, Brown, Navy Blue and Forest Green)--$60.00 

Troy Blanket Lining--$90.00

Harris Tweed Wool (North Sea Herringbone and Autumn Windowpane) and Broken Weave Tweed--$90.00

Buffalo Check Shetland Wool--$90.00

Alpaca Wool (Black, Grey and Medium Brown)--$80.00

Heavy Duty Shearling (Black, Dark Brown, Rust and Natural)--$200.00



There is a variety of color and style choices for hardware. Most zipper styles are available in nickel, brass, or antique brass finish. You can also choose from a variety of zipper sliders, such as bell pulls; ball and chain pulls; looped ball pulls; ring pulls; and diamond pulls.

Hookless Talon Zipper--$50.00 

Waldes Zipper--$50.00

Boxy NOS Talon--$30.00

Diamond Pull--$15.00 

Looped Ball Pull--$25.00

Universal Bell Pulls on Handwarmer Pockets--$40.00


Exterior and Interior Pockets

There are a variety of exterior pocket options for most jacket styles. Exterior pocket options range from the number of exterior pockets to the placement/angle of the exterior pockets.

Interior pockets can be a very useful addition to your custom jacket! Interior pockets are set vertically into the leather facing and can be specified with a zipper or snap closure, or open (no hardware). Fabric patch pockets are also available on certain types of linings.  All interior pockets are $45.00 each.



Many of Aero's styles can be made in a two-tone pattern! The most popular styles have been the Sunburst, J106, Highwayman and Cafe' Racer, but there are many other Aero styles that would be amazing as two-tone jackets. Ask us about this option and we'll help you design a one-of-a-kind look!


Snap-Off Fur Collars

Snap-off fur collars are available as an option on the Ridley, J106, J107, Daytona and other cross-zip motorcycle jackets.  Each collar is patterned and custom-made for the custom jacket.  Snap-off fur collars are $250.00.


Other options

There are typically other options that are unique to the jacket style you are ordering, and we will bring those features to your attention at the time of purchase. If you are wondering if a particular feature is available for your jacket, just ask!  Please keep in mind that pattern changes can add several weeks to production time for patterning.  Here are the pattern fees for some of the changes that customers request:

Change collar--$40.00

Add external pockets--$55.00 per pocket

Add handwarmers (two pockets)--$110.00

Add shoulder gussets--$100.00

Change yoke on back--$75.00

Full back design change--$150.00

Change cuff style (e.g. straight cuff to a button cuff)--$50.00

Change zipper front to button front (not available on all designs)--$100.00

Change front pocket design--$50 

Non-removeable mouton fur collar--$75.00

Add windflap--$60.00

Add throat latch (not available on all styles)--$50

Add epaulets (not available on all styles)--$50

Add corduroy hem (not available on all styles)--$40.00

Add leather back to Shackleton vest--$75.00 

Add Vicenza horsehide trim to military shearling jacket--$45.00


Extra items

There are a few items that you can purchase along with your custom jacket.  These items ship for FREE with your custom jacket delivery!

Lochcarron Lambswool Scarf ($40.00)-- Lochcarron Lambswool Scarf collection

Lochcarron Ties ($40.00)-- Lochcarron Tie collection

Aero Wooden Hanger ($15.00)

Beeswax--for CXL only ($15.00)

Aero Leather Bible Love art book ($120.00)


Customs, Import Fees and Shipping from Scotland 

No charge


Step Three: Final Approval and Production Schedule

Final approval for your custom order specifications is done via e-mail so that you will know exactly what you have ordered! Once you have given your final approval, the order goes into the next available production month.

Thurston Bros. has a monthly production allotment from Aero which keeps our wait times as short as possible! Our wait time is typically 6-8 weeks in the Spring and Summer months, and 10-14 weeks in the Fall and Winter months. When planning your Fall or Winter jacket order, keep the longer wait time in mind.  Neither we, nor Aero, can guarantee the wait time length due to circumstances that are out of our control. Please keep in mind that pattern changes can add several weeks to production time for patterning. Wait times are based on average customer experience and may be shorter or longer than the stated average.  We'll let you know at the time you place your order what the current wait time is, since these times are estimates and can vary from year to year.

To get started with a custom Aero order, email us at!  You can also purchase the jacket you want to custom order directly from the website and we'll contact you for more details.


Tips for a smooth fitting process:

1. US customers can purchase a return label for $39.99.  This price includes insurance and you will likely find it to be much less expensive than retail shipping from your location.  Here is the link to purchase the return label: RETURN LABEL

2. International customers may need to pay customs and import fees to their country.  Thurston is not able to pay these fees, nor do we have any control over the costs for customs and import fees to other countries.  If you are using our fit jacket process, make sure to save your paperwork so that you can either request a refund on any fees (for the fit jacket) or show proof of an exchange when you receive your custom jacket.

3. Make certain to purchase insurance for the return of the fit jacket.  Lost packages are rare and they are always a surprise.  Make sure you are covered!

4. When you box up the stock jacket for return, zip it up and fold it neatly.  There is a yellow instruction sheet in the box that has a guide for how to fold the jacket.  Crumpling up the jacket in the box can cause damage that cannot be undone!

5. Choose the fit for your custom jacket.  Thurston Bros will make recommendations based on many years of experience and fitting thousands of customers in leather jackets, but ultimately you will decide on the fit that works for you!  Our fit jackets are provided for your convenience and peace of mind in the ordering process.

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